Acoustical ceiling construction



April 17, 1956 J. E. STANLEY ACOUSTICAL CEILING CONSTRUCTION Filed March 18, 1952 v0 V. Mm 5 AN R TE 0 5V N A N w W J United States Patent '0 It 2,742,122 ACOUSTICAL CEILING CONSTRUCTION John E. Stanley, North Hollywood, Calif., assignor to Duo-Flex Corporation, Los Angeles, Calif., a corporation Application March 18, 1952, Serial No. 277,180 Claims. (Cl. 189--85) This invention relates to ceiling constructions, more particularly acoustical ceilings that are suspended from overhead building structures, and is directed to an acoustical ceiling construction that not only affords labor savings in installation cost but also provides structural advantages as a finished ceiling.

The basic feature of the present invention is the concept that important advantages may be afforded by forming the tiles with keris or longitudinal slots in their edge faces into which suitable means may beinserted for supporting the tiles. One important advantage is that in such an arrangement the supporting means that engages the tile does not mask any portion of the lower face of the tile to lower the acoustical efiiciency of the ceiling.

A further feature of the preferred practice of the pres ent invention is the concept of employing transverse auxiliary tile-supporting members to span the spaces between the parallel ceiling panel members for engagement with corresponding edges of the acoustical tile. Since the ends of such auxiliary supporting members impose loads at spaced points on the parallel ceiling panels, the ceiling panel members must be eflicient structural members. The proposed method of supporting the tiles by edge slots, however, makes it possible to use panels that are in the form of hollow beams of high efliciency with respectto rigidity and strength.

In accord with these concepts the panels are preferably in the form of sheet metal channels having upwardly extending legs or sideflanges that are offset inwardly to provide external shoulders and corresponding internal shoulders.

Since such hollow-beam panels may support loads concentrated at spaced points on their longitudinal shoulders, it is possible to support the acoustical tiles primarily if not entirely by means of the transverse auxiliary support members with no necessity for direct supporting connection between the tiles and the hollow-beam panels themselves. A feature of the invention stemming from this new method of supporting the acoustical tiles is that the tiles may merely abut the sides of the hollow-beam panels without overlap. This construction permits adjacent pairs of tiles to be pivotally moved upwardly for removal from the ceilingstructure whenever it is desired to gain access to an area above the ceiling tiles.

Preferably the arrangement is such that the bottom faces of the acoustical tiles are substantially flush with the bottom faces of the hollow-beam panels so that the surface of the whole ceiling is in one plane to give the ceiling the pleasing appearance of a smooth continuous surface. The desired alignment of the bottom face of a tile with the bottom face of the adjacent hollow beam panel is attained simply by making the vertical dimension from the bottom face of the hollow beam panel to the surface of the longitudinal shoulder of the hollow beam panel substantially equal to the vertical dimension from the bottom surface of the tile to the edge slot of the tile by which the tile is supported. The transverse auxiliary support members have horizontal side flanges that both extend into the edge slots of the tiles and rest on the longitudinal shoulders of the hollow-beam panels so that the described dimensioning results in the bottom faces of the tiles is flush with the bottom faces of the hollow-beam panels.

Preferably the auxiliary support members are in the form of what may be termed T-splines since they have the cross-sectional configuration of an inverted T. The inverted stem of the T provides the strength and rigidity required for support of the tiles. In the preferred practice of the invention a substantially air-tight ceiling construction is achieved by also using flat splines in the form of strips to serve as spacers on the support shoulders of the hollow-beam panels between the T-splines. One longitudinal extending half of each flat spline rests on a support shoulder of a hollow-beam panel and the other half extends into the edge slot of an adjacent tile.

The various features and advantages of the invention will be apparent in the following detailed description of the preferred practice of the invention considered with the accompanying drawings. In the drawings, which are to be regarded as merely illustrative:

Figure 1 is a perspective view of a portion of an acoustical ceiling constructed in accord with the teachings of the invention,

Figure 2 is a perspective view partly in. section showing how the various members of the new combination are inter-related in a ceiling construction for the support of acoustical tile,

Figure 3 is a perspective view of a preferred embodi ment of the hanger clip for supporting the hollow-beam panels from the overhead runner channels,

Figure 4 is a fragmentary sectional view, the section being taken transversely of one of the splines, and Figure 5 is a similar fragmentary sectional View taken transversely of a hollow-beam panel.

As shown in Figure 2 the principal parts of the struc tural combination for supporting the acoustical ceiling tiles include: a hollow-beam panel generally designated 10; a hanger member or hanger clip 11 to support the beam for an overhead runner channel 12; an auxiliary support member or spline generally designated 13; and, finally suitable flat splines 14 to serve as spacers between the T-splines 13.

The hollow-beam panel 10 is in the form of a channel member of suitable sheet metal having a web or bottom wall 18 and two upwardly extending legs or flanges 19, each of the side flanges being oifset to form an external longitudinal support shoulder 20 and a corresponding internal longitudinal shoulder 21. Thus the: interior of the hollow-beam panel has what may be termed the configuration of an inverted T.

Each hanger clip 11 is preferably made of suitable sheet material, such as suitably pliable sheet metal, and is cut to the general configuration of an inverted T to fit inside a hollow-beam panel 10. Thus, as best shown in Figure 3, the hanger clip is formed with two upwardly directed shoulders 25 to engage the corresponding downwardly directed interior shoulders 21 of the hollow-beam panel.

Such a sheet metal hanger clip may be adapted in any suitable manner for attachment to an overhead runner channel 3.2. In the preferred practice of the invention the hanger clip is adapted to be bent into permanent engagement with the runner channel by hand or by hand tools, the material of the hanger clip being suitably pliable for this purpose. In the particular construction shown, the hanger clip 11 is formed with a plurality of fingers adapted to be bent into permanent engagement with the upper and lower flanges, respectively, of the runner channel 12.

Thus, as best shown in Figure 3, the sheet metal of the hanger clip 11 is slit to form a broad central finger 26 flanked by two side fingers 27. The two side fingers 27 are bent substantially perpendicularly to extend under the bottom flange 28 of the runner channel 12 and the central 'finger 26 is bent to angular configuration in similar manner, asshown in Figure 3, to extend over the top flange-290i the -runnerchannel. lt can be seen that the vertical spacing between the two side fingers 27 and the central finger 26 of the hanger clip 11 is ubstantially equal -to"the"o.ver=all vertical dimens'iono'f the runner channel '12.

The hanger clip 'll may be readily engagedwith "the hollow-beam panel by's'imply' inserting the;clip into thedh-terior of the channel, the clip being turnedupon'its longitudinal axis: to make'such' insertion possible and: then being rotated-to'bringthetwo' shoulders 25 of the clip into engagement with the internal shoulders '21 of the hollow-beam panel. Theihanger ,clipmay 'then'be shifted longitudinally. along the'interior of the hollOw beam panel toapositionfiatagainst *the back.. of the runner channel 12 and then, by means of hand tools,-the two side fingers 27 'maybebent over into permanent engagement with the bottomflange 28 of the runner channel as bestshown inFigure 2. and'in similarmanner the central finger'26 mag "be bent over into engagementwith the top -flange'29 of the runner channel.

'Thetransverse support members or T-splines 13 may be fabricated in a simple manner from suitable. strips of sheet metal by folding each strip of metal on itself to form a double-thickness vertical web 33 and by bending the two thicknesses of metal respectively to formhorizontal' bottom flanges 3'4.

The flat splines 14 are substantially of thesame thick ness as the bottom flanges '34 of the splines 13and preferably are of a width on the order of twice the width of a support shoulder it} of a hollow-beampanel 10. Such flat splines may be madeof any suitable material. Fibrous sheet material may be employed. The splines are not depended upon to carry weight and therefore are not stressed to any significant degree.

The acoustical tiles, generally designated by numerals 3'5, areof more or less conventional construction but, for thepurpose of'thepresent invention, each tile is formed with alongitudinal kerf or slot 38 oneachoftwo opposite edge faces for engagement withthe flanges 34 of the T-splines as best showninFigure 4. In the presentpreferred practice of the invention, the other two parallel edgefaces of the acoustical tilearealso formed .with a slot 38 for engagement with flat splineslA. Thus by preference each tile 35 has a continuous slot 38 around itsfouredge faces.

The manner in which the described structuralelements may-be assembled for the installation of an acoustical ceiling may be readily understood from the foregoing description. By way of example, Figural shows a finished ceilingincorporating the structural members of the present invention.

In preparation for ithe installation of the ceiling in Figure 1, lengths ofconventional edge moulds 40 are installed onthe four walls ofthe roomat the desired ceilingllevel- Theedge moulds 40am of well known construction being in the form of angle members having vertical flanges 41 that are attached to the room walls by suitable screws and having horizontal flanges 42that extend around the margins of the finished ceiling.

After the edge moulds 40 are installed, the hollow-beam panels 10 are. installed byusing hanger clipsll to suspend the hollow-beam panels from the overhead runner channels 12in the manner heretofore described. The ends of the hollow-beam panels 10 at the opposite walls ofthe room restv on the horizontal flanges 42 of the corresponding edge moulds 4G. The spacing between two hollowbeam panels 10 conforms to the width of one row of the acoustical tiles.35. In the particular installation shown in Figural, the individual tiles 35 are of rectangular configuration being dimensioned 12 x 24". The individual tiles 35 are formedwith tapered grooves-44 on their, lower.

faces to dividetheirlower faces into two equal squares. Thus, as viewedfrom below, each tile 35 has the appearance of two separate square tiles. The hollow-beam panels 10 are spaced 24 inches apart measured -edge-to- 1 edge to accommodate the long dimensions of the rectangular tiles.

For economical use of material it is desirable that some means be providedto splice lengths of the hollow-beam panels 10-together. A feature of the invention in this respect .is "the useof whatmayzbetermed splicing sleeves that are dimensioned'and adapted to telescope into the abutting ends of two lengths of the hollow-beam panel'to splice the two lengths-:together. A-further featureof the invention is the concept of making such splicing-sleeves out of scrap lengths of the hollow-beam panel 10 by, in effect, crimping-,thescraplengths .to contract their crosssectional dimensions sufliciently forsnug fit-of.the splicing sleeves inside thee-nds of hollow-beam panels.

Figure 5 shows in.cross-section.a splicing sleeve, generally designated 45, that is crimpedor indentedtlongitudinally on each side as indicated at 46 forcontraction of thecross-sectional dimensions :to make therequired fit; Thecrimpingwperationmay be performed onsuitablezdies foraccurate and uniform results. When :manufacturedinthis mannerfor relatively close fit,,a splicing sleeveas. short as.8 inches in length is adequate for the purpose ,-.especially so because the hangerclips 11 afford such efficient. supportfor :the hollow-beam panels that little or no stress is imposed-Yon the splicing sleeves.

.When the. installation of the parallel-hollow-beampanels 10.,hasbeen completed, the T.-splines 13 are placed in parallelpositions-spanningthe spaces between the hollowbeam 1331161510,,1116 two horizontal bottom flanges 34 of theT-splines resting .at-each end on the corresponding horizontal support shoulders :24 of the hollow-beam panels. It is asimple matter to inserttheindividualflat splines 1.4.into ,thc rkerfs or slots.38 at'the opposite ends of. anacoustical tile 35.and totiltthe tile upward through the space between twosof the hollow-beam panels 10 and thenlower.the tile-toahQriZontal position. The two kerfs or slots 38 of the longer edge faces of the tile are then engaged with the -,corr esponding ,bottom 'flanges '34 of the ll-splines :13 .for: permanent support, the acoustical tilewith theflat-splinesldresting on thesupport shoulders panels mare substantially the same 'dlSi'fillClElbOVC thebottom. faces 18 0f thepanels, the bottom faces of the acoustical tiles; are substantially at the sarne=level as t the bottom faces of the-hollow-beam panels. Thus the surface of-the finished-ceiling lies, substantially in one plane.

.It ,is important .to note: that the full. area of :the individualsacoustical tileszware completely exposed soathatthe maximum acoustical effect of :the individual tiles is realized. The :onlyexception injthis respect is that-the long-itudi-naledges of the'tiles bordering on two ofthe side awalls-of then-corn rest on the:corresponding edge monlds-zdtlan d are thereby maskedto minor extent.

lt may readily beappreciated: that theresultingceil- The individual mechanical ,structure & in which a; network of metal frame membersjist-adequatelymanchored to-the building itself. Theaddition of the flat splines 14 to serve as spacers -between the T-splines 13- makes the ceiling substantially airz-tight, the ceiling being. superiorinthis respect.

As rt-he tiles :are pendantly supported between juxtaposed pairs of ,panclst-lt) by the splines 13, there is, as prev-iouslyrexplained, no overlapping of the tiles and panels. Thus, .asa'best shown inFigure'l, adjacent'pairs of tiles.;excep,t those disposeddirectly beneath the-channels 12 may be pivoted :upwardly in opposite directions to' disengage the adjoining edges of the tiles from the supporting spline whereupon the tiles may be removed from the ceiling. This feature of the present invention is important, as it permits easy access to areas above the ceiling tiles.

My description in specific detail of the presently preferred embodiment of the invention will suggest to those skilled in the art various changes, substitutions and other departures from my disclosure that properly lie within the spirit and scope of the appended claims.

I claim:

1. In a ceiling construction of the type described, comprising: a plurality of elongated main support panels, each having a planar lower face and presenting an upwardly facing continuous shoulder on each of its longitudinal sides and at a given distance from said planar lower face; means for securing said panels in spaced parallel relationship to the framework of a building; rows of ceiling surface forming tiles disposed between said panels, said tiles having a length substantially equal to the distance between the opposed outermost vertical surfaces of any pair of said panels; auxiliary support members intermediate each adjacent pair of tiles in a row, said auxiliary support members having their opposite end portions seated on the shoulders of adjacent panels; means carried by each auxiliary support member for engaging in kerfs formed in contiguous faces of adjacent tiles at said given distance from the lower faces of said tiles whereby said tiles are supported with the lower faces thereof substantially flush with the planar faces of said panels and the opposite end faces in facewise engagement with the adjacent side faces of juxtaposed panels; and a flat spline anchored in each of said end faces of the tiles and having one longitudinal half resting on the adjacent panel shoulder for sealing the space between the end faces of said tiles and the side faces of said panels.

2. In a demountable ceiling suspension construction of the type described, comprising: a plurality of hollow elongtaed main support panels, each having a planar lower face with planar side faces normal thereto and presenting an upwardly facing continuous shoulder on each of its longitudinal sides and at a given distance from said planar lower face; each panel including an extension directed upwardly from the inner edge of each shoulder to provide surfaces inset from said side faces; means for securing said panels in spaced parallel relationship to the framework of a building; rows of ceiling surface-forming tiles disposed between said panels, said tiles having planar end faces and each being of a length equal to the distance between adjacent side faces of juxtaposed panels whereby the planar end faces of said tiles facewisely engage with adjacent side faces of juxtaposed panels; auxiliary support members intermediate each adjacent pair of tiles of a row, said auxiliary support members having a length greater than the distance between a side face of one panel and the inset surface of the juxtaposed panel and having their opposite end portions seated on the shoulders of juxtaposed panels; and oppositely projecting flange means carried by each auxiliary support member engaging in kerfs formed in contiguous faces of adjacent tiles at such a distance from the lower faces of said tiles that said tiles are pendantly supported solely by said auxiliary support means with the lower faces of said tiles substantially flush with the planar faces of said panels.

3. In a demountable ceiling suspension construction of the type described, comprising: a plurality of hollow elongate main support panels, each having a planar lower face with planar side faces normal thereto and presenting an upwardly facing continuous shoulder on each of its longitudinal sides and at a given distance from said planar lower face; means for securing said panels in spaced parallel relationship to the frame work of a building; rows of ceiling surface-forming tiles disposed between said panels and spanning the distance between adjacent side faces of juxtaposed panels, said tiles having planar end faces facewisely engaged with said adjacent side faces of juxtaposed panels; auxiliary support members intermediate each adjacent pair of tiles of a row and having their opposite end portions seated on the shoulder of juxtaposed panels whereby said auxiliary support rnembers are supported by said panels; means forming a part of each panel and cooperative with said auxiliary support mernbers for holding said auxiliary support members against a longitudinal movement sufficient to disengage an opposite end of said auxiliary support member from the shoulder engaged thereby; and means carried by each auxiliary support member engaging in kerfs formed in contiguous faces of adjacent tiles at such a distance from the lower faces of said tiles that said tiles are pendantly supported between juxtaposed main support panels solely by said auxiliary support members with the lower faces of i said tiles substantially flush with the planar lower faces of said panels.

4. in a ceiling construction as recited in claim 3 wherein said means forming a part of each panel includes a flange extending upwardly from the inner edge of each shoulder to cooperate with said auxiliary support members for holding said auxiliary support members against a longitudinal movement suflicient to disengage an opposite end of said auxiliary support member from the shoulder engaged thereby, said upwardly extending flanges in combination with said planar side faces providing weight supporting structural rigidity for said panels.

5. A ceiling construction in a building structure, comprising: a plurality of rectangular ceiling tiles arranged in rows, each having a kerf on at least two side edges parallel to its bottom face and at a given distance from its bottom face; a plurality of spaced parallel ceiling panels positioned as spacers between rows of said tiles in edge-to-edge abutment with the tiles, each of said panels having a bottom face substantially flush with the bottom faces of the tiles, each of said panels having an upwardly facing longitudinal shoulder on each of its two longitudinal sides at substantially said given distance from said bottom face of the panel; hanger members extending from above to said panels and supporting the panels from the building structure; auxiliary support members perpendicular to said panels spanning the spaces between the panels and extending between each pair of successive rows of the tiles, said auxiliary support members having their opposite ends resting on said shoulders of the panels and having the configuration of an inverted T providing side flanges extending into the kerfs of the tiles as sole supports for the tiles, and fiat splines perpendicular to said auxiliary support members and spanning the spaces therebetween, each of said splines having approximately one longitudinal half resting on one of said panel shoulders and the other approximate longitudinal half extending into a kerf formed in the adjacent tile.

References Cited in the file of this patent UNITED STATES PATENTS 1,218,283 La Morte Mar. 6, 1917 1,439,167 Higgin Dec. 19, 1922 1,714,681 Loucks May 28, 1929 1,897,776 Venzie Feb. 4, 1933 2,028,272 Burgess Jan. 21, 1936 2,101,952 Olsen Dec. 14, 1937 2,152,418 Olsen Mar. 28, 1939 2,270,268 Chambers Jan. 20, 1942 2,309,695 Droeger Feb. 2, 1943 2,318,092 Olsen May 4, 1943 2,406,315 Blocher Aug. 27, 1946 2,481,794 Stitt Sept. 13, 1949 2,485,090 Finch Oct. 18, 1949 2,499,278 Olsen Feb. 28, 1950 2,648,102 Jacobson Aug. 11,1953

FOREIGN PATENTS 987,118 France Apr. 11, 1951 

